KOLARC MX600 User manual

OWNER'S MANUAL
Operational Manual-OM
2023−02
Processes
Multiprocess Welding
Visit our website at
MX600
MX500
MX400

2
Contents......................................................................................................................................................................................2
Safety Instructions......................................................................................................................................................................4
Explanation of Safety Instructions...............................................................................................................................................................4
General...................................................................................................................................................................................................4
Intended Use............................................................................................................................................................................................4
Safety Symbols.........................................................................................................................................................................................5
Environmental Conditions.........................................................................................................................................................................6
Obligations of the Operating Company.....................................................................................................................................................6
Obligations of Personnel...........................................................................................................................................................................6
Grid Connection.......................................................................................................................................................................................6
Personal Protection and Protection of Others..............................................................................................................................................7
Danger from toxic gases and vapors..........................................................................................................................................................7
Danger from Flying Sparks........................................................................................................................................................................8
Risks from grid current and welding current................................................................................................................................................8
Stray welding currents...............................................................................................................................................................................9
EMC Device Classifications......................................................................................................................................................................10
EMC Measures.......................................................................................................................................................................................10
EMF measures........................................................................................................................................................................................11
Particular Hazard Areas..........................................................................................................................................................................11
Requirement for the shielding gas............................................................................................................................................................12
Danger from Shielding Gas Cylinders......................................................................................................................................................12
Danger Posed by Shielding Gas Leak.......................................................................................................................................................13
Safety Measures at the Setup Location and During Transport......................................................................................................................13
Safety Measures in Normal Operation.....................................................................................................................................................13
Maintenance and repair..........................................................................................................................................................................14
Safety Inspection.....................................................................................................................................................................................14
Disposal.................................................................................................................................................................................................15
Safety Symbols.......................................................................................................................................................................................15
Data backup..........................................................................................................................................................................................15
Copyright...............................................................................................................................................................................................15
Declaration of conformity........................................................................................................................................................................16
Introduction..............................................................................................................................................................................17
Overview...............................................................................................................................................................................................17
Duty Cycle.............................................................................................................................................................................................19
Selecting a Distance................................................................................................................................................................................19
Connection Input Power............................................................................................................................................................20
General.................................................................................................................................................................................................20
Safety.....................................................................................................................................................................................................20
Connect the mains cable.........................................................................................................................................................................20
Receptacle Information............................................................................................................................................................................21
Generator-Powered Operation................................................................................................................................................21
Generrator powered operation................................................................................................................................................................21
Commissioning.........................................................................................................................................................................22
Safety.....................................................................................................................................................................................................22
General ................................................................................................................................................................................................22
Information on system components.........................................................................................................................................................22
Welding processes and procedures for MIG/MAG welding.....................................................................................................22
General.................................................................................................................................................................................................22
Brief description of MIG/MAG standard synergic welding..........................................................................................................................22
Brief description of MIG/MAG pulsed synergic welding..............................................................................................................................23
Brief description of Duo Pulse / Position welding.......................................................................................................................................23
Brief description the gouging (Arc Air Gouging)........................................................................................................................................23
System Components..................................................................................................................................................................23
General.................................................................................................................................................................................................23
Safety.....................................................................................................................................................................................................23
VRD: Safety principle...............................................................................................................................................................................24
Control Panel.........................................................................................................................................................................................25
Control Panel.........................................................................................................................................................................................26
Job List / Function Graphic / Function List................................................................................................................................................27
Connections, switches and mechanical components................................................................................................................28
Side view................................................................................................................................................................................................28
MX600 /MX500/ MX400 powersupply front / rear view.............................................................................................................................29
Minimum equipment for welding operations...........................................................................................................................30
General.................................................................................................................................................................................................30
Gas-cooled MIG/MAG welding...............................................................................................................................................................30
Water-cooled Mıg/mag welding..............................................................................................................................................................30
Manual metal arc welding.......................................................................................................................................................................30
Minimum equipment for arc air gouging..................................................................................................................................................30
Contents

3
Before Installation And Initial Operatin...................................................................................................................................31
Safety.....................................................................................................................................................................................................31
Intended use .........................................................................................................................................................................................31
Setup regulations....................................................................................................................................................................................31
Assembling system components (overview)...............................................................................................................................................32
Place the wirefeeder on the power source.................................................................................................................................................33
Connecting the interconnecting hosepack................................................................................................................................................33
Correct routing of the interconnecting hosepack.......................................................................................................................................33
Establishing a ground earth connection....................................................................................................................................................33
Connect the gas cylinder.........................................................................................................................................................................34
Brake Cylinder..........................................................................................................................................................................35
Brake cylinder components......................................................................................................................................................................35
Wire feeding reel....................................................................................................................................................................................35
Feed rollers placement / changing...........................................................................................................................................................36
MIG/MAG Welding....................................................................................................................................................................37
Safety.....................................................................................................................................................................................................37
Preparation............................................................................................................................................................................................37
Overview................................................................................................................................................................................................37
MIG / MAG Synergic Welding...................................................................................................................................................38
MIG / MAG Synergic welding..................................................................................................................................................................38
XDeep / XRoot / XCold............................................................................................................................................................................39
XStabil / Position / Duo Pulse...................................................................................................................................................................40
Corrections during welding......................................................................................................................................................................41
Manual Metal Arc Welding.......................................................................................................................................................42
Safety.....................................................................................................................................................................................................42
Preparation............................................................................................................................................................................................42
Manual metal arc (MMA) welding............................................................................................................................................................43
Corrections during welding......................................................................................................................................................................43
HotStart function (F25)............................................................................................................................................................................44
Anti-Stick function (F28)..........................................................................................................................................................................44
Arc Air Gauging........................................................................................................................................................................45
Safety.....................................................................................................................................................................................................45
Preparation............................................................................................................................................................................................45
Arc air gouging......................................................................................................................................................................................45
Electrical Diagram....................................................................................................................................................................46
Electrical Diagram..................................................................................................................................................................................47
Querying the source circuit inductance....................................................................................................................................49
General information...............................................................................................................................................................................49
Welding circuit its inductance shows.........................................................................................................................................................49
Of the hose package correctly positioned.................................................................................................................................................49
Troubleshooting........................................................................................................................................................................50
Error resolution table...............................................................................................................................................................51

4
Safety Instructions
Explanation of
Safety
Instructions
DANGER!
Indicates an immediate danger.
▶ Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶ Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶ Minor injury or damage to property may result if appropriate precautions are not
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to
recognized safety standards. If used incorrectly or misused, however, it can cause
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section
headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.

5
Safety Symbols
FUMES AND GASES can be hazardous.
ARC RAYS can burn eyes and skin.
WELDING can cause fire or explosion.
BUILDUP OF GAS can injure or kill.
NOISE can damage hearing.
CYLINDERS can explodeifdamaged.
FIRE OR EXPLOSION hazard.
FALLING UNIT can cause injury.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
FLYING METAL or DIRT can injure eyes.
ELECTRIC SHOCK can kill.
HOT PARTS can cause severe burns.
READ INSTRUCTIONS.
FLYING SPARKS can cause injury.
STATIC (ESD) can damage PC boards.
MOVING PARTS can cause injury.
WELDING WIRE can cause injury.
ARC WELDING can cause interference.
EXPLODING PARTS can cause injury.
SHOCK HAZARD from testing.
MOVING PARTS can cause injury.
OVERUSE can cause OVERHEATING.
H.F. RADIATION can cause interference.

6
All persons who are assigned to work with the device must do the following before beginning
the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can
occur in one’s absence.
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section
"Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer accepts no liability for any
damage resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in
accordance with the intended purpose." The manufacturer is not responsible for any
damage resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Obligations of the
Operating
Company
Obligations of
Personnel
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current
consumption.

7
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and during
the welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
This may affect a number of device types in terms of:
- connection restrictions
- criteria regarding maximum permissible grid impedance *)
- criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Personal
Protection
and Protection
of Others
Danger from
toxic gases and
vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from
the International Agency for Research on Cancer.
Keep your head out of the welding fumes and gases.

8
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers, as well
as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating wirefeeder
holder.
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or protected with a
certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if
these have not been prepared in accordance with corresponding national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/were
stored. Residues pose a risk of explosion.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least
20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the
measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
- The welding process used
Consult the corresponding material safety data sheets and manufacturer’s instructions for the compo-
nents listed above.
Recommendations for exposure scenarios, risk management measures and identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
Danger from
Flying Sparks
Risks from grid
current and
welding
current

9
Ensure suitable personal protection with dry temporary backing or cover with sufficient
insulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned.
Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180° around the
longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- Never immerse it in liquids to cool it
- Never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the electrodes of two
welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in
some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground
conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector system with ground
conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket without a
ground conductor contact is only permitted if all national regulations for protective separation
are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for
any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched on again
by applying a clearly legible and understandable warning sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will switch off the main
switch at the correct time.
Stray welding
currents
If the following instructions are not observed, stray welding currents may occur, which
pose a risk of the following:
- Fire
- Overheating of components connected to the workpiece
- Destruction of ground conductors
- Damage to the device and other electrical equipment
Ensure that the workpiece terminal is securely connected to the workpiece.
Secure the workpiece terminal as close to the spot to be welded as possible.

10
Position the device with sufficient insulation against electrically conductive environments,
e.g., insulation against electrically conductive floors or electrically conductive mounts.
Observe the following when using electrical distributors, double-headed retainers, etc.:
Even the electrode of the welding torch/electrode holder not in use carries electric potential.
Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the welding wire
drum, large spool or wirespool to the wirefeeder with insulation.
EMC Device
Classifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.
EMC Measures In certain cases, even though a device complies with the standard limit values for emissions,
it may affect the application area for which it was designed (e.g., when there is
sensitive equipment at the same location, or if the site where the device is installed is
close to either radio or television receivers). If this is the case, then the operating company is obliged
to take appropriate action to rectify the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance
with national and international provisions. Examples of interference-prone equipment
that could be affected by the device:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation

11
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- fans
- gears
- rollers
- shafts
- wirespools and welding wires.
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed, and all side parts have been mounted properly.
- Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of injury (cuts to the hand,
facial and eye injuries, etc.)
Therefore always hold the welding torch away from the body (devices with wirefeeder) and use suitable
protective goggles.
Do not touch the workpiece during or after welding—burning hazard.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective equipment
when reworking workpieces and ensure that other persons are sufficiently protected.
Leave the welding torch and other parts with a high operating temperature to cool before working on
them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g. boilers) must be labeled with the
symbol (Safety). However, the power source may not be located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections
for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data sheet. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
Only use suitable load-carrying equipment from the manufacturer when transporting
devices by crane.
- Attach chains or ropes to all designated attachments of the suitable load-carrying
equipment.
- Chains or ropes must be the smallest angle possible from vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the
immediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large
as possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them
around one's body or body parts
Particular Hazard
Areas

12
Especially with ring lines, contaminated shielding gas can cause damage to equipment
and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 μm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
In the event of crane attachment of the wirefeeder during welding, always use a suitable, insulating
wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by
hand. The carrier belt is not suitable for transport by crane, counterbalanced lift truck or other
mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association with the device or its
components, must be checked regularly (e.g. for mechanical damage, corrosion, or changes due to
other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and
guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the
shielding gas connection. Use suitable Teflon tape to seal the thread of the shielding gas connection
adapter on the device side before installation.
Requirement for
the shielding gas
Danger from
Shielding Gas
Cylinders
Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding gas cylinders
are an integral part of the welding equipment, so they must be handled very carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag,
open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they
cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the correct matching
accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that
are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.
Follow the manufacturer’s instructions and applicable national and international provisions for
shielding gas cylinders and accessories.

13
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace is always
clean and organized.
Only set up and operate the device in accordance with the protection class shown on the rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to
allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident prevention
regulations are observed when transporting the device, especially guidelines concerning hazards
during transport and shipment.
Before transporting the device, completely drain the coolant and dismantle the following components:
- wirefeeder
- wirespool
- shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage after it has been
transported but before commissioning. Have any damage repaired by trained service technicians
before commissioning the device.
Danger Posed by
Shielding Gas
Leak
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air
in the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least
20 m³ per hour.
- Please observe the safety and maintenance information for the shielding gas cylinder
or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the
main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before each start-up.
Safety Measures
at the Setup Lo-
cation
and During
Transport
Safety Measures
in Normal
Operation
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is switched on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage
and functionality of the safety devices.

14
The manufacturer recommends that a safety inspection of the device be performed at least every 12
months.
The manufacturer recommends calibrating power sources within the same 12-month interval.
A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, care, and maintenance
- At least every 12 months
For the safety inspection, follow the appropriate national and international standards and guidelines.
You can obtain more information about the safety inspection and calibration from your service center.
The service center will provide the necessary documents upon request.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's
consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
Always secure the shielding gas cylinder well and remove before transporting by crane.
Only the original coolant from the manufacturer is suitable for use in our devices due to
its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the manufacturer accepts
no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in certain
conditions. Only transport the coolant in closed original containers and keep away from sources of
ignition.
Properly dispose of used coolant according to national and international regulations. The coolant
safety data sheet can be obtained from your service center or via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
Maintenance and
repair
Safety Inspection

15
Safety Symbols Devices with the CE label satisfy the essential requirements of the low-voltage and electromagnetic
compatibility directive (e.g. relevant product standards of the EN 60974 series).
Kolarc International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the following
website: http://www.kolarc.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada
and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The
manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Kolarc reserves the right to make changes.
The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the
part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that
you have found in the Operating Instructions, we will be most grateful for your comments.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national law,
electrical equipment that has reached the end of its life must be collected separately and returned to
an approved recycling facility. Any device that you no longer require must be returned to your dealer,
or you must locate the approved collection and recycling facilities in your area. Ignoring this European
Directive may have potentially adverse affects on the environment and your health!

16
Kolarc Makine İmalat Sanayi ve Ticaret AŞ
2022-04-16
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
We KOLARC MAKİNE İMALAT SAN. VE TİC. A. Ş: 2014. Cd. No: 8/1, 06930 Alcı
Osb/Sincan/Ankara, declares that the product(s) identified in this declaration conform to
the essential requirements and provisions of the stated Standard(s).
Product/Apparatus Identification:
Standards
• IEC 60974 -1:2021 Arc welding equipment - Part1: Welding power sources
• IEC 60974 -10:2020 Arc welding equipment - Part10: Electromagnetic compatibility
(EMC) requirements
Product- MX600
- MX500
- MX400
Signatory:
İlker OLUCAK
General Manager
Date of Declaration

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Introduction
(1) Wirefeeder (MX4)
(2) Power source (MX600/MX500/MX400)
(3) Cooling unit (WX)
Overview
A modular design and ability to easily extend the system guarantee a high degree of flexibility. The
device is designed for the following welding processes:
- MIG/MAG Manual
- TIG (Lift Arc)
- MMA
- Gouging

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Welding is dangerous. The following basic
requirements must be met:
- Adequate welding qualifications
- Appropriate protective equipment
- Exclusion of unauthorized persons
Do not use the functions described here until you have
fully read and understood the following
documents:
- These Operating Instructions
- All system component Operating Instructions,
especially the safety rules

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Duty Cycle
18 in (460 mm)
18 in (460 mm)
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit
overheats, output stops, a Help message is displayed and cooling fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or voltage, or duty cycle before welding.
6 Minutes Welding 4 Minutes Resting
60% Duty Cycle
Overheating 0
15
A or V
OR
Reduce Duty Cycle
Minutes
Selecting a Distance

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Connecting Input Power
Power source Cable cross-section
MX600 Pulse AWG 12 *) 4x6
MX500 Pulse AWG 10 *) 4x6
MX400 Pulse AWG 10 *) 4x4
Strain-relief devices for other cable cross-sections must be designed accordingly.
General
Connect the mains
cable
If no mains cable is connected, a mains cable that is suitable for the connection voltage
must be fitted before commissioning.
A strain-relief device for the following cable cross-sections is fitted to the power source:
Safety WARNING!
Danger from work that is not carried out properly.
This can result in severe personal injury and damage to property.
▶The work described below may only be performed by trained specialist personnel.
▶ Follow national standards and guidelines.
CAUTION!
Danger from improperly prepared mains cable.
Short circuits and damage to property may result.
▶ Fit ferrules to all phase conductors and the ground conductor of the stripped mains
cable.
Input Conductors (L1, L2 and L3)
Connect the input conductors to
separate the L1, L2 and L3
device line terminals.
L 1
L 2
L 3
Yellow and Green (Earth ground)